Service Procedure
A. Inspect the Right and Left Headlamp Harness1. Open the hood.
2. Remove and save the air cleaner housing.
3. Remove and save the headlamp low beam bulb access covers from the right and left headlamp housing.
4. Turn the low beam headlamp bulb turn counterclockwise and remove the headlamp assembly from the right and left headlamp housing.
CAUTION:
Do not touch the glass section of the headlamp bulb.
5. Disconnect the headlamp wiring harness from the headlamp bulb:
> If both the right and left side weather seal on the headlamp wiring harness connectors are red, no further action is required. Assemble the headlamp assemblies and continue with Section C. Inspect and/or Relocate Antilock Brake System (ABS)/Electronic Stability Control (ESC) Fuse.
> If the right and/or left weather seal is black, the headlamp wiring harnesses must be replaced. Continue with Section B. Replace Headlamp Wiring Harness.
B. Replace Headlamp Wiring Harness
NOTE:
All pictures were taken with the headlamp assembly removed from the vehicle for clarity purposes only. DO NOT REMOVE THE HEADLAMP ASSEMBLIES FROM THE VEHICLE.
1. Open the trunk and disconnect the negative battery cable at the battery.
2. Open the hood.
3. Remove and save the high beam bulb access cover.
4. Disconnect the 4-way headlamp wiring harness connector from the body wiring harness (Figure 2).
5. Using two 24 inch long pieces of mechanics wire (or equivalent), connect one end of the mechanics wire to each of the headlamp bulb connectors (Figure 3).
6. Unclip the 4-way headlamp wiring harness connector from the back of the headlamp housing (Figure 3).
7. Disengage the headlamp wiring harness lock on the headlamp housing by turning it turn counterclockwise (Figure 3).
8. Carefully guide the headlamp bulb wiring harnesses out of the headlamp housing with the mechanics wire attached (Figure 4).
9. Disconnect the mechanics wire from the original headlamp bulb connectors.
10. Discard the original headlamp wiring harness.
11. Connect the new headlamp wiring harness to the mechanics wire.
NOTE:
The connector with the red connector seal is for the low beam bulb.
12. Using the mechanics wire, pull the new headlamp wiring harness into position inside the headlamp housing (Figure 4).
13. Disconnect and save the mechanics wire from each headlamp bulb connector.
14. Inspect both low beam headlamp bulbs for damage. Replace low beam headlamp bulb(s) if damage or corrosion is found.
15. Install the headlamp bulbs into the headlamp bulb connectors. Then install the headlamp bulb connectors.
16. Engage the headlamp wiring harness lock into the headlamp housing (Figure 5).
17. Clip the 4-way headlamp wiring harness connector to the headlamp housing (Figure 6).
18. Install the headlamp bulb access covers.
19. Connect the 4-way headlamp wiring harness connector to the body wiring harness.
20. Repeat Steps 3 through 18 on the other headlamp assembly.
21. Install the air cleaner housing.
22. Continue with Section C - Inspect and/or Relocate Antilock Brake System (ABS)/Electronic Stability HEADLAMP Control (ESC) Fuse.
C. Inspect and/or Relocate Antilock Brake System (ABS)/Electronic Stability Control (ESC) Fuse
1. Remove the Power Distribution Center (PDC) cover.
2. Check for the presence of a 25 amp cartridge fuse (Figure 7) in PDC location number 6:
> If PDC location number 6 has a 25 amp cartridge fuse, a fuse upgrade is not required. Install the PDC cover and continue with:
> For 2011 models, Section D. Replace Exterior Front Door Handles.
> For 2012 models, No further action is required. Return the vehicle to the customer.
> If PDC location number 6 does not have a 25 amp cartridge fuse, a fuse upgrade is required. Continue with Step 3 of this procedure.
3. Disengage the retaining tabs that secures the PDC to the mounting bracket (Figure 8).
4. Disconnect the main B+ battery feed wire on the PDC (Figure 8).
5. Remove and save the PDC mounting bracket.
6. Turn the PDC over to expose the bottom side of the PDC.
7. Carefully open the PDC bottom cover (Figure 9).
8. Using a small pick tool, remove and discard the black plastic terminal lock (Figure 9).
9. Insert the blade terminal provided in the repair kit into cavity number 6 of the PDC (Figure 10).
10. Install the new black plastic terminal lock provided in the repair kit (Figure 10).
11. Locate the red wire located in cavity 14 (Figure 11). Place a mark on the wire approximately 35 mm up from the blade terminal.
12. Cut the wire at the mark made in Step 11.
13. Place the clear shrink tube provided in the repair kit over the remaining wire in cavity 14 of the PDC. Apply heat to the shrink tube to seal the end of the wire (Figure 11).
14. Strip approximately 10 -15 mm of insulation from the end of the remaining cut wire.
15. Place the black shrink tube provided in the repair kit over the remaining cut wire.
16. Using the supplied splice band clamp and crimp tool 10042, crimp the wire that had the insulation stripped in Step 14 to the wire that was added in Step 9 (Figure 12).
17. Solder the crimp installed in Step 16 with rosin core solder (Figure 13).
18. Slide the shrink tube over the splice and apply heat to the shrink tube until glue comes out of both ends of the shrink tube.
19. Install the bottom PDC cover.
20. Install the PDC mounting bracket.
21. Snap the PDC into position on the mounting bracket.
22. Connect the main B+ battery feed to the PDC. Tighten the retaining nut to 106 in.lbs. (12 Nm).
23. Remove and discard the white 25 amp mini fuse located in cavity number 14 of the PDC (Figure 14).
24. Install the new fuse supplied in the repair kit into cavity number 6 of the PDC (Figure 14).
25. Install the new fuse location stickers supplied in the repair kit onto the fuse location diagram on the inside of PDC cover (Figure 15).
NOTE:
Four stickers are supplied in the kit, but only two are required.
26. Install the PDC cover onto the PDC.
27. Connect the negative battery cable to the battery.
28. Connect the wiTECH scan tool and clear all Diagnostic Trouble Codes (DTCs).
29. Start the vehicle and verify that the ABS light, brake light and ESP light in the instrument cluster turn off after the initial "bulb check."
30. For 2011 models, continue with Section D. Replace Exterior Front Door Handles.
31. For 2012 models, no further action is required. Return the vehicle to the customer.
D. Replace Exterior Front Door Handles (2011 Models Only)
1. Open the drivers front door.
2. Remove and save the front door handle retaining screw access hole plug (Figure 16).
3. Using a T20 Torx driver, loosen (but do not remove) the exterior front door handle retaining screw (Figure 17).
4. Carefully pull the front exterior door handle out of the exterior door handle pocket (Figure 18).
5. Disconnect the electrical connector from the front exterior door handle electrical receptacle (Figure 19).
6. Remove and discard the original front exterior door handle.
7. Place the new front exterior door handle up to the front door and connect the electrical connector to the front exterior door handle electrical receptacle (Figure 19).
8. Place the new front exterior door handle into position in the front exterior door handle pocket (Figure 18).
9. Carefully tighten the front exterior door handle retaining screw (Figure 17).
10. Install the front door handle retaining screw access hole plug (Figure 16).
11. Repeat steps 1 through 10 on the passenger side front exterior door handle.
12. Return the vehicle to the customer